CN113758419A - Laser calibration die machining system and method - Google Patents
Laser calibration die machining system and method Download PDFInfo
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- CN113758419A CN113758419A CN202111048021.7A CN202111048021A CN113758419A CN 113758419 A CN113758419 A CN 113758419A CN 202111048021 A CN202111048021 A CN 202111048021A CN 113758419 A CN113758419 A CN 113758419A
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- 238000003754 machining Methods 0.000 title claims abstract description 63
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000012545 processing Methods 0.000 claims abstract description 49
- 238000012986 modification Methods 0.000 claims abstract description 45
- 230000004048 modification Effects 0.000 claims abstract description 45
- 238000001514 detection method Methods 0.000 claims abstract description 44
- 238000003801 milling Methods 0.000 claims abstract description 16
- 238000001179 sorption measurement Methods 0.000 claims description 21
- 239000000654 additive Substances 0.000 claims description 18
- 230000000996 additive effect Effects 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 18
- 238000003860 storage Methods 0.000 claims description 18
- 238000007789 sealing Methods 0.000 claims description 12
- 238000004372 laser cladding Methods 0.000 claims description 9
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 6
- 230000033001 locomotion Effects 0.000 claims description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 3
- 239000004793 Polystyrene Substances 0.000 claims description 3
- 239000004809 Teflon Substances 0.000 claims description 3
- 229920006362 Teflon® Polymers 0.000 claims description 3
- 239000011324 bead Substances 0.000 claims description 3
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 3
- 239000001569 carbon dioxide Substances 0.000 claims description 3
- 238000001914 filtration Methods 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 230000003287 optical effect Effects 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 239000004417 polycarbonate Substances 0.000 claims description 3
- 229920000515 polycarbonate Polymers 0.000 claims description 3
- 229920002223 polystyrene Polymers 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 230000003014 reinforcing effect Effects 0.000 claims description 3
- 238000011065 in-situ storage Methods 0.000 abstract description 5
- 238000003672 processing method Methods 0.000 abstract 1
- 235000013372 meat Nutrition 0.000 description 6
- 238000005520 cutting process Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/002—Measuring arrangements characterised by the use of optical techniques for measuring two or more coordinates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
Abstract
The invention relates to a laser calibration die processing system and a laser calibration die processing method. The machining, laser calibration and surface modification are integrated on one device, and the in-situ treatment of a plurality of procedures can be realized only by one precise electric control table, so that the machining precision is higher, and the operations of calibrating and positioning a model and the like during each machining are omitted; by using the designed laser calibration method, the calibration is more accurate and the calibration speed is higher, the range selection is more scientific when the precision detection is carried out, and the processing speed is improved while the processing precision is ensured; the precise electric control table with double fixation is arranged, negative pressure and magnetic force are used for double fixation, a workpiece is fixed more firmly, turning and milling can be carried out in situ, and other machining means and equipment, such as a five-axis linkage machining center and the like, can be added according to needs.
Description
Technical Field
The invention relates to the field of material processing, in particular to a laser calibration die processing system and method.
Background
The existing laser calibration method is generally based on solving internal and external parameters of a camera by using a Zhangyingyou multi-plane calibration method, and then realizes laser calibration, but the existing method needs a large amount of calculation and is difficult to realize high-precision laser calibration. The high-precision laser calibration is realized by using single-point laser calibration, and the structured light range is large but the precision is insufficient. And the traditional single-point laser calibration mode is too slow.
The publication number CN113145674A discloses a method for marking a center with high laser accuracy in drawing die processing, which combines a three-point positioning and clamping method with two-wheel three-section laser positioning and distance measurement, and drives a universal ball to continuously roll around the ring side of the die by a motor, thereby expanding the application range.
Publication No. CN109940270A discloses a seven-axis five-linkage ultrafast laser processing system, which is composed of a laser light source, a light beam transmission system, a galvanometer processing head, a five-axis motion system, a structured light three-dimensional online monitoring system, a power real-time online detection component, a light path alignment component and the like.
The method can realize in-situ calibration detection in the machining process, but the calibration detection process is complex and the precision is limited.
Disclosure of Invention
In view of the above, to solve the above problems, a laser calibration mold processing system is provided, which includes a control center, a precise electronic console, a laser calibration module, a machining module, a surface modification module, a model storage module, and a coordinate calculation module.
The precise electric control platform is used for placing a die to be processed, and can perform XY two-dimensional movement in the horizontal direction and rotate around any point on the surface of the electric control platform;
the machining module is used for carrying out precision machining on the die, and comprises turning and milling;
the laser calibration module is used for carrying out laser calibration on the die in the machining process and detecting the machining size precision;
the surface modification module is used for carrying out surface modification on the surface of the die;
the model storage module is used for storing a 3D model of the die to be processed and providing a calibration reference for the laser calibration module;
and the coordinate calculation module is used for calculating the deviation of the laser point according to the detection result of the laser calibration module and generating a single-point deviation graph.
The precise electric control console, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module are connected with the control center; the control center controls the precise electric control platform, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module to work.
The laser calibration module comprises a laser emitter and a calibration CCD camera, the positions of the laser emitter and the calibration CCD camera are fixed, and the direction of a laser spot of laser emitted by the laser emitter is fixed; an optical filter is arranged in front of the calibration CCD camera and used for filtering light outside the wavelength emitted by the laser emitter;
calibrating the pixels imaged by the CCD camera, namely, the position of each pixel corresponds to a spatial coordinate point of a plane where the precise electric console is located; namely, any one laser spot shot by the calibration CCD camera is directly converted into a spatial coordinate point of the plane where the precise electric control platform is located in the calibration CCD camera and is output to the control center.
The machining module comprises a turning tool and a milling tool, the turning direction of the turning tool is parallel to the precise electric control table, and the milling direction of the milling tool is perpendicular to the precise electric control table;
the precise electric control platform comprises a negative pressure adsorption hole and a powerful electromagnet inner core; the negative pressure adsorption hole is used for carrying out negative pressure adsorption and fixation on a die to be processed on the precise electric control platform, and the strong electromagnet inner core is used for carrying out magnetic fixation on the die to be processed on the precise electric control platform;
the quantity of negative pressure adsorption hole is a plurality of, and accurate automatically controlled platform is furnished with the sealing rubber ring of multiple shape, and the sealing rubber ring is used for placing between treating mold processing and accurate automatically controlled platform to guarantee to treat the leakproofness between mold processing and the accurate automatically controlled platform, guarantee that the negative pressure adsorption hole can firmly fix treating mold processing and accurate automatically controlled platform.
The model storage module stores a 3D model of a mold to be processed, and the control center calls the 3D model from the storage module and sends the 3D model to the coordinate calculation module; the coordinate calculation module calculates a standard coordinate point of a light spot in a calibration CCD camera, wherein the light spot is projected by the laser calibration module and reaches the surface of the die to be processed, according to the position relation among the 3D model, the precise electric control platform and the laser calibration module;
and comparing the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculating an offset vector from the standard coordinate point to the actual coordinate point, and sending the offset vector to the control center.
A method for processing a die by utilizing a laser calibration die processing system comprises the following steps:
step 1: polishing the bottom of the mold to be processed, and processing a smooth plane at the bottom of the mold to be processed, wherein the shape of the smooth plane is the same as that of the sealing rubber ring, so as to ensure that the mold to be processed and the precise electric control platform can be firmly fixed by the negative pressure adsorption hole;
placing a die to be processed on the surface of the precise electric control platform, connecting the middle of the die to be processed at intervals by using a sealing rubber ring, starting the negative pressure of the negative pressure adsorption hole, and ensuring that the die to be processed and the precise electric control platform are firmly fixed; then starting the inner core of the strong electromagnet, and further reinforcing the die to be processed by utilizing magnetic force;
step 2: the precise electric control table drives the die to be processed to move, and the machining module processes the die to be processed into a preset shape;
and step 3: selecting any number of detection points on the die to be processed, and carrying out coarse detection; the coordinate calculation module calculates a standard coordinate point (X0, Y0) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the 3D model, the precise electric control platform and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
and 4, step 4: the control center calculates the die of each offset vector, if the die of any offset vector is within the allowable range, the die to be processed is qualified, and the surface modification is directly carried out;
if the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X0, Y0) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
after the precision detection, machining the area to be unqualified again according to the precision detection result until the machining requirement is met;
aiming at the calibration of machining, the situation of 'fleshiness' or 'fleshiness' may exist, aiming at the situation of fleshiness, the machining of cutting or milling is directly carried out, aiming at the situation of fleshiness, if the fleshiness is not too much, the processing is not needed, and the next step is directly carried out; if the meat is much lacking, the workpiece is rejected, and the condition of the meat lack is judged according to a threshold value. The so-called fleshiness means that more material remains at the site and further cutting is required; what is called meat loss is excessive material removal.
And 5: the surface modification module drives the additive processing head to perform additive surface modification; performing ultrahigh-speed laser cladding on the additive machining head, and performing surface modification on the surface of the die; carrying out secondary machining on the surface-modified die;
step 6: selecting any number of detection points on the die to be processed after the step 5, and performing coarse detection; the coordinate calculation module calculates a standard coordinate point (X1, Y1) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the modified 3D model, the precise electric control console and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
the control center calculates the mode of each offset vector, and if the mode of any offset vector is within the allowable range, the mode to be processed is qualified.
If the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X1, Y1) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
and after the precision detection, carrying out surface modification and machining again on the to-be-unqualified area according to the precision detection result until the machining requirement is met.
Aiming at the calibration of surface modification, the situation of 'fleshiness' or 'fleshiness' may exist, aiming at the situation of fleshiness, the mechanical processing is directly carried out, aiming at the situation of fleshiness, the secondary surface modification is needed to be carried out firstly, and the mechanical processing is carried out after materials are added on the surface of the material.
The method for carrying out ultrahigh-speed laser cladding on the surface modification module comprises the steps that the additive processing head moves horizontally and is matched with the horizontal plane of the precise electric control platform to rotate so as to realize ultrahigh-speed laser cladding, a carbon dioxide laser is used for the additive processing head, and a material sprayed by the additive processing head is a special surface modification material for the die.
The special surface modification material for the die comprises the following components in percentage by weight: 30-40% of Teflon powder, 15-20% of micron-sized heat-resistant glass beads, 20-30% of polystyrene, 10-15% of polyvinyl chloride, 10-15% of polycarbonate and 10-20% of iron powder.
The laser emitter and the calibration CCD camera are both provided with choppers for synchronizing the laser emitter and the calibration CCD camera.
The invention has the beneficial effects that:
the invention integrates the machining, laser calibration and surface modification on one device, can realize the in-situ treatment of a plurality of procedures only by one precise electric control table, has higher processing precision, and saves the operations of positioning the calibration and the like of the model during each processing; by using the designed laser calibration method, the calibration is more accurate and the calibration speed is higher, the range selection is more scientific when the precision detection is carried out, and the processing speed is improved while the processing precision is ensured; the precise electric control table with double fixation is arranged, negative pressure and magnetic force are used for double fixation, a workpiece is fixed more firmly, turning and milling can be carried out in situ, and other machining means and equipment, such as a five-axis linkage machining center and the like, can be added according to needs.
Drawings
FIG. 1 is a schematic diagram of the overall architecture of the present invention;
FIG. 2 is a schematic diagram of a calibration structure of the present invention;
FIG. 3 is an offset illustration of the present invention, including fleshy and fleshy situations.
Detailed Description
The advantages, features and methods of accomplishing the same will become apparent from the drawings and the detailed description that follows.
Example 1:
a laser calibration die processing system comprises a control center, a precise electric control table, a laser calibration module, a machining module, a surface modification module, a model storage module and a coordinate calculation module.
The precise electric control platform is used for placing a die to be processed, and can perform XY two-dimensional movement in the horizontal direction and rotate around any point on the surface of the electric control platform;
the machining module is used for carrying out precision machining on the die, and comprises turning and milling;
the laser calibration module is used for carrying out laser calibration on the die in the machining process and detecting the machining size precision;
the surface modification module is used for carrying out surface modification on the surface of the die;
the model storage module is used for storing a 3D model of the die to be processed and providing a calibration reference for the laser calibration module;
and the coordinate calculation module is used for calculating the deviation of the laser point according to the detection result of the laser calibration module and generating a single-point deviation graph.
The precise electric control console, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module are connected with the control center; the control center controls the precise electric control platform, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module to work.
The laser calibration module comprises a laser emitter and a calibration CCD camera, the positions of the laser emitter and the calibration CCD camera are fixed, and the direction of a laser spot of laser emitted by the laser emitter is fixed; an optical filter is arranged in front of the calibration CCD camera and used for filtering light outside the wavelength emitted by the laser emitter;
calibrating the pixels imaged by the CCD camera, namely, the position of each pixel corresponds to a spatial coordinate point of a plane where the precise electric console is located; namely, any one laser spot shot by the calibration CCD camera is directly converted into a spatial coordinate point of the plane where the precise electric control platform is located in the calibration CCD camera and is output to the control center.
The machining module comprises a turning tool and a milling tool, the turning direction of the turning tool is parallel to the precise electric control table, and the milling direction of the milling tool is perpendicular to the precise electric control table;
the precise electric control platform comprises a negative pressure adsorption hole and a powerful electromagnet inner core; the negative pressure adsorption hole is used for carrying out negative pressure adsorption and fixation on a die to be processed on the precise electric control platform, and the strong electromagnet inner core is used for carrying out magnetic fixation on the die to be processed on the precise electric control platform;
the quantity of negative pressure adsorption hole is a plurality of, and accurate automatically controlled platform is furnished with the sealing rubber ring of multiple shape, and the sealing rubber ring is used for placing between treating mold processing and accurate automatically controlled platform to guarantee to treat the leakproofness between mold processing and the accurate automatically controlled platform, guarantee that the negative pressure adsorption hole can firmly fix treating mold processing and accurate automatically controlled platform.
The model storage module stores a 3D model of a mold to be processed, and the control center calls the 3D model from the storage module and sends the 3D model to the coordinate calculation module; the coordinate calculation module calculates a standard coordinate point of a light spot in a calibration CCD camera, wherein the light spot is projected by the laser calibration module and reaches the surface of the die to be processed, according to the position relation among the 3D model, the precise electric control platform and the laser calibration module;
and comparing the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculating an offset vector from the standard coordinate point to the actual coordinate point, and sending the offset vector to the control center.
Example 2:
a method for processing a die by utilizing a laser calibration die processing system comprises the following steps:
step 1: polishing the bottom of the mold to be processed, and processing a smooth plane at the bottom of the mold to be processed, wherein the shape of the smooth plane is the same as that of the sealing rubber ring, so as to ensure that the mold to be processed and the precise electric control platform can be firmly fixed by the negative pressure adsorption hole;
placing a die to be processed on the surface of the precise electric control platform, connecting the middle of the die to be processed at intervals by using a sealing rubber ring, starting the negative pressure of the negative pressure adsorption hole, and ensuring that the die to be processed and the precise electric control platform are firmly fixed; then starting the inner core of the strong electromagnet, and further reinforcing the die to be processed by utilizing magnetic force;
step 2: the precise electric control table drives the die to be processed to move, and the machining module processes the die to be processed into a preset shape;
and step 3: selecting any number of detection points on the die to be processed, and carrying out coarse detection; the coordinate calculation module calculates a standard coordinate point (X0, Y0) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the 3D model, the precise electric control platform and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
and 4, step 4: the control center calculates the die of each offset vector, if the die of any offset vector is within the allowable range, the die to be processed is qualified, and the surface modification is directly carried out;
if the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X0, Y0) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
after the precision detection, machining the area to be unqualified again according to the precision detection result until the machining requirement is met;
aiming at the calibration of machining, the situation of 'fleshiness' or 'fleshiness' may exist, aiming at the situation of fleshiness, the machining of cutting or milling is directly carried out, aiming at the situation of fleshiness, if the fleshiness is not too much, the processing is not needed, and the next step is directly carried out; if the meat is much lacking, the workpiece is rejected, and the condition of the meat lack is judged according to a threshold value. The so-called fleshiness means that more material remains at the site and further cutting is required; what is called meat loss is excessive material removal.
And 5: the surface modification module drives the additive processing head to perform additive surface modification; performing ultrahigh-speed laser cladding on the additive machining head, and performing surface modification on the surface of the die; carrying out secondary machining on the surface-modified die;
step 6: selecting any number of detection points on the die to be processed after the step 5, and performing coarse detection; the coordinate calculation module calculates a standard coordinate point (X1, Y1) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the modified 3D model, the precise electric control console and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
the control center calculates the mode of each offset vector, and if the mode of any offset vector is within the allowable range, the mode to be processed is qualified.
If the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X1, Y1) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
and after the precision detection, carrying out surface modification and machining again on the to-be-unqualified area according to the precision detection result until the machining requirement is met.
Aiming at the calibration of surface modification, the situation of 'fleshiness' or 'fleshiness' may exist, aiming at the situation of fleshiness, the mechanical processing is directly carried out, aiming at the situation of fleshiness, the secondary surface modification is needed to be carried out firstly, and the mechanical processing is carried out after materials are added on the surface of the material.
The method for carrying out ultrahigh-speed laser cladding on the surface modification module comprises the steps that the additive processing head moves horizontally and is matched with the horizontal plane of the precise electric control platform to rotate so as to realize ultrahigh-speed laser cladding, a carbon dioxide laser is used for the additive processing head, and a material sprayed by the additive processing head is a special surface modification material for the die.
The special surface modification material for the die comprises the following components in percentage by weight: 30-40% of Teflon powder, 15-20% of micron-sized heat-resistant glass beads, 20-30% of polystyrene, 10-15% of polyvinyl chloride, 10-15% of polycarbonate and 10-20% of iron powder.
The laser emitter and the calibration CCD camera are both provided with choppers for synchronizing the laser emitter and the calibration CCD camera.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (8)
1. A laser calibration mould processing system comprises a control center, a precise electric control platform, a laser calibration module, a machining module, a surface modification module, a model storage module and a coordinate calculation module; the method is characterized in that:
the precise electric control platform is used for placing a die to be processed, and can perform XY two-dimensional movement in the horizontal direction and rotate around any point on the surface of the electric control platform;
the machining module is used for carrying out precision machining on the die, and comprises turning and milling;
the laser calibration module is used for carrying out laser calibration on the die in the machining process and detecting the machining size precision;
the surface modification module is used for carrying out surface modification on the surface of the die;
the model storage module is used for storing a 3D model of the die to be processed and providing a calibration reference for the laser calibration module;
the coordinate calculation module is used for calculating the deviation of the laser point according to the detection result of the laser calibration module and generating a single-point deviation graph;
the precise electric control console, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module are connected with the control center; the control center controls the precise electric control platform, the laser calibration module, the machining module, the surface modification module, the model storage module and the coordinate calculation module to work.
2. The laser calibration die machining system of claim 1, wherein:
the laser calibration module comprises a laser emitter and a calibration CCD camera, the positions of the laser emitter and the calibration CCD camera are fixed, and the direction of a laser spot of laser emitted by the laser emitter is fixed; an optical filter is arranged in front of the calibration CCD camera and used for filtering light outside the wavelength emitted by the laser emitter;
calibrating the pixels imaged by the CCD camera, namely, the position of each pixel corresponds to a spatial coordinate point of a plane where the precise electric console is located; namely, any one laser spot shot by the calibration CCD camera is directly converted into a spatial coordinate point of the plane where the precise electric control platform is located in the calibration CCD camera and is output to the control center.
3. The laser calibration die machining system of claim 1, wherein:
the machining module comprises a turning tool and a milling tool, the turning direction of the turning tool is parallel to the precise electric control table, and the milling direction of the milling tool is perpendicular to the precise electric control table;
the precise electric control platform comprises a negative pressure adsorption hole and a powerful electromagnet inner core; the negative pressure adsorption hole is used for carrying out negative pressure adsorption and fixation on a die to be processed on the precise electric control platform, and the strong electromagnet inner core is used for carrying out magnetic fixation on the die to be processed on the precise electric control platform;
the quantity of negative pressure adsorption hole is a plurality of, and accurate automatically controlled platform is furnished with the sealing rubber ring of multiple shape, and the sealing rubber ring is used for placing between treating mold processing and accurate automatically controlled platform to guarantee to treat the leakproofness between mold processing and the accurate automatically controlled platform, guarantee that the negative pressure adsorption hole can firmly fix treating mold processing and accurate automatically controlled platform.
4. The laser calibration die machining system of claim 2, wherein:
the model storage module stores a 3D model of a mold to be processed, and the control center calls the 3D model from the storage module and sends the 3D model to the coordinate calculation module; the coordinate calculation module calculates a standard coordinate point of a light spot in a calibration CCD camera, wherein the light spot is projected by the laser calibration module and reaches the surface of the die to be processed, according to the position relation among the 3D model, the precise electric control platform and the laser calibration module;
and comparing the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculating an offset vector from the standard coordinate point to the actual coordinate point, and sending the offset vector to the control center.
5. A method of die machining using the laser calibration die machining system of any of claims 1-4, comprising the steps of:
step 1: polishing the bottom of the mold to be processed, and processing a smooth plane at the bottom of the mold to be processed, wherein the shape of the smooth plane is the same as that of the sealing rubber ring, so as to ensure that the mold to be processed and the precise electric control platform can be firmly fixed by the negative pressure adsorption hole; placing a die to be processed on the surface of the precise electric control platform, connecting the middle of the die to be processed at intervals by using a sealing rubber ring, starting the negative pressure of the negative pressure adsorption hole, and ensuring that the die to be processed and the precise electric control platform are firmly fixed; then starting the inner core of the strong electromagnet, and further reinforcing the die to be processed by utilizing magnetic force;
step 2: the precise electric control table drives the die to be processed to move, and the machining module processes the die to be processed into a preset shape;
and step 3: selecting any number of detection points on the die to be processed, and carrying out coarse detection; the coordinate calculation module calculates a standard coordinate point (X0, Y0) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the 3D model, the precise electric control platform and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
and 4, step 4: the control center calculates the die of each offset vector, if the die of any offset vector is within the allowable range, the die to be processed is qualified, and the surface modification is directly carried out;
if the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X0, Y0) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
after the precision detection, machining the area to be unqualified again according to the precision detection result until the machining requirement is met;
and 5: the surface modification module drives the additive processing head to perform additive surface modification; performing ultrahigh-speed laser cladding on the additive machining head, and performing surface modification on the surface of the die; carrying out secondary machining on the surface-modified die;
step 6: selecting any number of detection points on the die to be processed after the step 5, and performing coarse detection; the coordinate calculation module calculates a standard coordinate point (X1, Y1) of a light spot of a laser which is projected by the laser calibration module and reaches the surface of the die to be processed in the calibration CCD camera according to the position relation among the modified 3D model, the precise electric control console and the laser calibration module; the laser calibration module is used for calibrating a to-be-machined mould by laser, the laser emitter emits a beam of laser, the laser reaches the surface of the to-be-machined mould to form a laser spot, the calibration CCD camera is used for shooting an image of the spot, and the shot laser spot is directly converted into a spatial coordinate point of a plane where the precision electric control platform is located in the calibration CCD camera and output to the control center;
the coordinate calculation module compares the actual coordinate point measured by the laser calibration module with the standard coordinate point, calculates the offset vector from the standard coordinate point to the actual coordinate point, and sends the offset vector to the control center;
the control center calculates the mode of each offset vector, and if the mode of any offset vector is within the allowable range, the mode to be processed is qualified;
if the mode of any offset vector exceeds the threshold value, the laser calibration module is controlled to carry out precision detection on the vicinity of the unqualified detection point: controlling a precise electric console to rotate a circle by taking a standard coordinate point (X1, Y1) of an unqualified point as a center of the circle, continuously detecting an offset vector of the point, drawing an offset vector A into an offset graph, wherein the drawing method is that a clockwise rotation angle is set as theta, (Acos theta, Asin theta) is set as a coordinate point to draw the offset graph, the theta is more than or equal to 0 and less than or equal to 2 pi, and then selecting not less than 100 points in a defined range of the offset graph to measure the offset vector;
and after the precision detection, carrying out surface modification and machining again on the to-be-unqualified area according to the precision detection result until the machining requirement is met.
6. The method of mold tooling of claim 5 wherein:
the method for carrying out ultrahigh-speed laser cladding on the surface modification module comprises the steps that the additive processing head moves horizontally and is matched with the horizontal plane of the precise electric control platform to rotate so as to realize ultrahigh-speed laser cladding, a carbon dioxide laser is used for the additive processing head, and a material sprayed by the additive processing head is a special surface modification material for the die.
7. The method of mold tooling of claim 6 wherein:
the special surface modification material for the die comprises the following components in percentage by weight: 30-40% of Teflon powder, 15-20% of micron-sized heat-resistant glass beads, 20-30% of polystyrene, 10-15% of polyvinyl chloride, 10-15% of polycarbonate and 10-20% of iron powder.
8. The method of mold tooling of claim 6 wherein:
the laser emitter and the calibration CCD camera are both provided with choppers for synchronizing the laser emitter and the calibration CCD camera.
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